w o µ u ] v p } v } y ly w o v ^ u o · mss sp-58 pipe hangers and supports - materials, design...

Pat

[Pick the date]

tƭǳƳōƛƴƎ /ƻƴǘǊŀŎǘƻǊ v!κv/ tƭŀƴ {ŀƳǇƭŜ Selected pages (not a complete plan)

Part 1: Project‐Specific Quality Plan

Part 2: Quality Manual

Part 3: Submittal Forms

Part 4: LƴǎǇŜŎǘƛƻƴ /ƘŜŎƪƭƛǎǘ CƻǊƳǎ

Contact:

FirstTimeQuality 410‐451‐8006

Questions? Call First Time Quality 410-451-8006

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[ProjectName] - [ProjectNumber] Copyright

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PROJECT-SPECIFIC PLUMBING QUALITY PLAN

TABLE OF CONTENTS Background Information ........................................................................................................................ 7

Customer .................................................................................................................................................... 7

Project Name .............................................................................................................................................. 7

Project Number .......................................................................................................................................... 7

Project Location .......................................................................................................................................... 7

Overall Project Description ......................................................................................................................... 7

[CompanyName] Scope of Work ................................................................................................................ 7

A. [CompanyName] Quality Policy ......................................................................................................... 8

B. Key Elements of the Plumbing Quality Plan ........................................................................................ 9

Project Quality Assurance/Quality Control Plan Overview ...................................................................... 12

C. Project Quality Coordination and Communication ............................................................................ 13

D. Project QC Personnel ....................................................................................................................... 17

Project QC Job Position Assignments ....................................................................................................... 17

Project QC Organization Chart ................................................................................................................. 18

E. Duties, Responsibilities, and Authority of QC Personnel ................................................................... 19

F. Personnel Qualifications and Technical Certifications ....................................................................... 25

Personnel Certification Requirements ..................................................................................................... 26

G. Qualification of Third Party Inspection/Testing Companies and Subcontractors and Suppliers ......... 28

Plumbing Inspection/Testing Laboratory Qualification Requirements .................................................... 28

Qualification ............................................................................................................................................. 28

Purchase Order Approval ......................................................................................................................... 29

H. Quality Training .............................................................................................................................. 31

I. Plumbing Project Quality Specifications ............................................................................................ 34

Local construction Codes .......................................................................................................................... 34

Compliance with Industry Plumbing Standards........................................................................................ 35

J. Material Inspection Traceability and Quality Controls ....................................................................... 38

Identification of Lot Controlled Materials ................................................................................................ 38

Material Receiving and Inspection ........................................................................................................... 38

K. Plumbing Inspection and Test Plan .................................................................................................. 42

Inspection and Testing Plumbing Standards ............................................................................................ 43

Calibration of Inspection, Measuring, and Test Equipment ..................................................................... 44

L. Work Task Quality Inspections ......................................................................................................... 47

Identification of Quality Inspected Work Tasks ........................................................................................ 47

Required Inspections For Each Work Task ............................................................................................... 47

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Daily Quality Control Report ..................................................................................................................... 48

M. Control of Corrections and Nonconformances ................................................................................. 52

Marking of Nonconformances and Observations ..................................................................................... 52

Control the Continuation of Work ............................................................................................................ 52

Recording of Nonconformances ............................................................................................................... 52

Quality Manager Disposition of Nonconformance Reports ..................................................................... 53

Corrective Actions .................................................................................................................................... 53

Nonconformance Preventive Actions ....................................................................................................... 54

N. Project Completion Inspections ....................................................................................................... 56

Punch-Out QC Inspection ......................................................................................................................... 56

Pre-Final Customer Inspection ................................................................................................................. 56

Final Acceptance Customer Inspection .................................................................................................... 57

O. Project Quality Records and Documents .......................................................................................... 60

P. Quality Assurance Surveillance ........................................................................................................ 63

Project Quality Performance Surveillance ................................................................................................ 63

Project Quality Audits ............................................................................................................................... 63

Project Audit Plan ..................................................................................................................................... 64

Project Audit Requirements ..................................................................................................................... 64

Q. Additional Quality Control Requirements ........................................................................................ 66

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I. PLUMBING PROJECT QUALITY SPECIFICATIONS Fulfilling customer contract expectations is a primary objective of the [CompanyName] Quality System. To

ensure that customer expectations will be fulfilled, [CompanyName] clearly defines the requirements for

each contract before it is approved.

The Project Manager ensures that the information in customer contracts clearly defines customer

expectations and that the necessary details are provided to set requirements for construction.

[CompanyName] personnel and subcontractors and suppliers are accountable for compliance to

standards-based written specifications.

To achieve expectations reliably and consistently, specifications are clearly spelled out, not only for results

but also for processes. Specifications apply to materials, work steps, qualified personnel and

subcontractors and suppliers, safe work rules, and environmental work conditions.

Standards ensure that results are specified rather than left to discretionary practices.

All [CompanyName] construction activities comply with generally accepted good workmanship practices

and industry standards.

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COMPLIANCE WITH INDUSTRY PLUMBING STANDARDS Codes that may apply to this project include those listed below.

Regulatory Codes and Industry Standards

Division Description Reference Standard No.

Reference Standard Title 22 Installation of plastic pipe where in

compliance with NFPA PPFA-01 Firestopping: Plastic Pipe in Fire Resistive Construction

22 Brazed joints AWS B2.2/B2.2M Specification for Brazing Procedure and Performance Qualification

22 Soldered joints ASME B31.5 Refrigeration Piping and Heat Transfer Components

22 Corrosion protection coatings for buried pipe and fittings

NACE SP0169 Control of External Corrosion on Underground or Submerged Metallic Piping Systems

22 Installation of pipe hangers, inserts and supports

MSS SP-58 Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

22 Beveling, alignment, heat treatment, and inspection of weld

ASME B31.1 Power Piping

22 33

Installation of gas-fired water heater and gas piping

NFPA 54 National Fuel Gas Code

22 Installation of oil-fired water heater NFPA 31 Standard for the Installation of Oil-Burning Equipment

22 Installation of fixtures for use by the physically handicapped

ICC/ANSI A117.1 Accessible and Usable Buildings and Facilities

22 Backflow preventers installation ICC IPC International Plumbing Code

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[CompanyName][CompanySuffix] Quality Inspection and Test Plan

Project ID Project Name CONTRACTOR

[ProjectNumber] [ProjectName] [CompanyName]

SPECIFICATION SECTION

AND PARAGRAPH

NUMBER SCHEDULE ACTIVITY ID TEST REQUIRED

ACCREDITED/ APPROVED

LAB YES /NO SAMPLED BY TESTED BY

LOCATION OF TEST ON/OFF SITE/SITE

DATE COMPLETED

DATE FORWARDED

TO CUSTOMER REMARKS

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L. WORK TASK QUALITY INSPECTIONS [CompanyName] identifies a list of work tasks which will be quality controlled. Each work task is subject to

a series of inspections; before, during, and after completion.

Each inspection verifies compliance with full scope of the relevant specifications; not limited to inspection

form checkpoints.

The initial work task-ready inspection occurs when work is ready to start and ensures that work begins

only when it does not adversely impact quality results.

Incoming material inspections verify that materials are as specified and meet all requirements necessary

to assure quality results.

Work-in-process inspections continuously verify that work conforms to project specifications and quality

expectations. Work continues only when it does not adversely impact quality results.

At completion of the work task an inspection verifies that work has been completed in accordance with

project quality requirements.

Inspection results are recorded and maintained as part of the project files.

The Quality Manager identifies each Task that is a phase of construction that requires separate quality

controls to assure and control quality results. Each Task triggers as set of requirements for quality control

inspections before, during and after work tasks.

Independent quality audits are conducted to verify that the task quality controls are operating effectively.

Construction projects may execute a work task multiple times in a project, in which case a series of quality

inspections are required for each work task.

Independent quality control audits are conducted to verify that the task quality controls are operating

effectively.

IDENTIFICATION OF QUALITY INSPECTED WORK TASKS A listing of project work tasks is included on the Quality Control work task List and included as an exhibit

in this subsection.

REQUIRED INSPECTIONS FOR EACH WORK TASK Each work task is subject to a series of inspections before, during, and at completion as described below.

Results of inspections are recorded.

PREPARATORY SITE INSPECTION

The Superintendent performs a quality inspection of the work area and:

Assesses completion of required prior work

Verifies field measurements

Assures availability and receiving quality inspection status of required materials

Identifies any nonconformances to the requirements for the task to begin

Identifies potential problems

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TASK-READY INSPECTIONS

For each work task, the Superintendent or a qualified inspector performs job-ready quality inspections to

ensure that work activities begin only when they should begin. Job-ready quality inspections verify that

conditions conform to the project quality requirements.

WORK IN PROCESS QUALITY INSPECTIONS

For each work task, the Superintendent or a qualified inspector performs an initial work in process

inspection when the first representative portion of a work activity is completed.

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QUALITY MANUAL

TABLE OF CONTENTS

1. Quality System Management and Responsibilities ............................................................................. 6

1.1. Overview .............................................................................................................................................. 6

1.2. [CompanyName][CompanySuffix] Quality Policy ................................................................................ 6

1.3. Quality Duties, Responsibilities, and Authority ................................................................................... 6

1.4. Quality System Performance Measures .............................................................................................. 9

1.5. Customer Satisfaction Performance Measures ................................................................................... 9

1.6. Exceptions ............................................................................................................................................ 9

2. Project Quality Assurance/Quality Control Plan ............................................................................... 10

2.1. Overview ............................................................................................................................................ 10

2.2. [CompanyName] Project License and Qualification Requirements .................................................. 10

2.3. Project Personnel and Qualifications ................................................................................................ 11

2.4. Project Quality Assurance/Quality Control Plan ................................................................................ 11

2.5. Identification of Quality Controlled Work Tasks ............................................................................... 12

2.6. Project Quality Inspection and Test Plan ........................................................................................... 12

2.7. Project Quality Communications Plan ............................................................................................... 12

2.8. Project Quality Training Plan ............................................................................................................. 12

2.9. Customer Training On Operation and Maintenance ......................................................................... 12

2.10. Project Records and Documentation Plan ....................................................................................... 13

2.11. Project Audit Plan ............................................................................................................................ 13

3. Contract Specifications .................................................................................................................... 14

3.1. Overview ............................................................................................................................................ 14

3.2. Contract Technical Specifications ...................................................................................................... 14

3.3. Contract Drawings ............................................................................................................................. 14

3.4. Contract Submittals ........................................................................................................................... 14

3.5. Customer Submittal Approval ........................................................................................................... 16

3.6. Contract Warranty ............................................................................................................................. 16

3.7. Contract Review and Approval .......................................................................................................... 17

4. Design Review and Control .............................................................................................................. 18

4.1. Overview ............................................................................................................................................ 18

4.2. Design Input Review .......................................................................................................................... 18

4.3. Project Design Quality Assurance/Quality Control Plan .................................................................... 18

4.4. Design Progress Reviews ................................................................................................................... 19

4.5. Design Output Verification and Approval .......................................................................................... 19

5. Project-Specific Quality Standards ................................................................................................... 20

5.1. Overview ............................................................................................................................................ 20

5.2. Regulatory Codes ............................................................................................................................... 20

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5.3. Industry Quality Standards ................................................................................................................ 20

5.4. Material and Equipment Specifications ............................................................................................. 20

5.5. Work Process Specifications .............................................................................................................. 21

5.6. Controlled Material Identification and Traceability .......................................................................... 21

5.7. Measuring Device Control and Calibration ........................................................................................ 21

5.8. [CompanyName] Quality Standards .................................................................................................. 22

5.9. Application of Multiple Sources of Specifications ............................................................................. 22

6. Project Purchasing ........................................................................................................................... 23

6.1. Overview ............................................................................................................................................ 23

6.2. Qualification of Outside Organizations and Company Departments ................................................ 23

6.3. Quality Responsibilities of Key Subcontractor and Supplier Personnel ............................................ 24

6.4. Requirements for Subcontractor QC Plan ......................................................................................... 25

6.5. Subcontractor and Supplier Quality Policy ........................................................................................ 25

6.6. Project Subcontractor and Supplier List ............................................................................................ 26

6.7. Purchase Order Requirements .......................................................................................................... 26

6.8. Project Purchase Order Approvals .................................................................................................... 26

7. Process Controls .............................................................................................................................. 27

7.1. Overview ............................................................................................................................................ 27

7.2. Project Startup and Quality Control Coordination Meeting .............................................................. 27

7.3. Preparatory Project Quality Assurance/Quality Control Plan Planning ............................................. 27

7.4. Weekly Quality Planning and Coordination Meetings ....................................................................... 28

7.5. Process Control Standards ................................................................................................................. 28

7.6. Daily Quality Control Report .............................................................................................................. 30

7.7. Monthly Quality Control Report ........................................................................................................ 30

8. Inspections and Tests ....................................................................................................................... 31

8.1. Overview ............................................................................................................................................ 31

8.2. Required Work Task Quality Inspections and Tests........................................................................... 31

8.3. Material Inspections and Tests .......................................................................................................... 31

8.4. Work in Process Inspections .............................................................................................................. 32

8.5. Work Task Completion Inspections ................................................................................................... 32

8.6. Inspection of Special Processes ......................................................................................................... 33

8.7. Independent Measurement and Tests .............................................................................................. 33

8.8. Commissioning Functional Acceptance Tests .................................................................................... 33

8.9. Hold Points for Customer Inspection ................................................................................................. 33

8.10. Quality Inspection and Test Specifications ...................................................................................... 33

8.11. Inspection and Test Acceptance Criteria ......................................................................................... 33

8.12. Inspection and Test Status............................................................................................................... 34

8.13. Independent Quality Assurance Inspections ................................................................................... 34

8.14. Inspection and Test Records ............................................................................................................ 34

8.15. Project Completion and Closeout Inspection .................................................................................. 35

9. Nonconformances and Corrective Actions ........................................................................................ 37

9.1. Overview ............................................................................................................................................ 37

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9.2. Nonconformances ............................................................................................................................. 37

9.3. Corrective Actions ............................................................................................................................. 38

10. Preventive Actions ......................................................................................................................... 40

10.1. Overview .......................................................................................................................................... 40

10.2. Identify Preventive Actions for Improvement ................................................................................. 40

10.3. Train Preventive Actions for Improvement ..................................................................................... 40

11. Quality System Audits .................................................................................................................... 42

11.1. Overview .......................................................................................................................................... 42

11.2. Project Quality System Audit ........................................................................................................... 42

11.3. Company-wide Quality System Audit .............................................................................................. 42

12. Record and Document Controls ...................................................................................................... 43

12.1. Overview .......................................................................................................................................... 43

12.2. Quality System Documents ............................................................................................................. 43

12.3. Document Controls .......................................................................................................................... 43

12.4. Record Controls ............................................................................................................................... 44

13. Appendix ....................................................................................................................................... 45

13.1. Definitions of Terms ........................................................................................................................ 45

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7. PROCESS CONTROLS HOW WORK IS CARRIED OUT

7.1. OVERVIEW

The construction process plan defines how project work is to be done and approved for the overall

project. The construction process plan is communicated to all key personnel, subcontractors and suppliers

in a startup meeting. As the project proceeds, work task plans provide additional details of how each

individual work task is carried out. Work tasks planning meetings are used to communicate expectations

of the work task plan to key personnel responsible for carrying out the work task.

7.2. PROJECT STARTUP AND QUALITY CONTROL COORDINATION MEETING

Prior to the commencement of work, the Project Manager holds a meeting to discuss and coordinate how

project work will be performed and controlled. Key personnel from [CompanyName], subcontractors and

suppliers meet to review expectations for project quality results as well as quality assurance and quality

control policies and procedures including:

Key requirements of the project

The Project Quality Assurance/Quality Control Plan

Required quality inspections and tests

The project submittal schedule

Quality policies and heightened awareness of critical quality requirements

Project organization chart and job responsibilities

Methods of communication and contact information

Location of project documents and records

7.3. PREPARATORY PROJECT QUALITY ASSURANCE/QUALITY CONTROL PLAN PLANNING

7.3.1. WORK TASK REQUIREMENTS REVIEW

In preparation for the start of an upcoming work task, the Superintendent reviews an integrated and

coordinated set of documents that collectively define quality requirements for the work task including:

Objectives and acceptance criteria of the work task

Quality standards that apply to the work task

Work instructions, process steps, and product installation instructions that apply to the work task

Shop drawings

Submittals

Tools and equipment necessary to perform the work

License, certification, or other qualification requirements of personnel assigned to work

Required records of the process and resulting product

The subcontractor contracted to perform the work, if applicable

Customer contract requirements

Required quality inspections and tests

Method for clearly marking nonconformances to prevent inadvertent use

Location of quality system records and documents

Personnel training

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7.3.2. PREPARATORY SITE INSPECTION

The Superintendent also performs a quality inspection of the work area and:

Assesses completion of required prior work

Verifies field measurements

Assures availability and receiving quality inspection status of required materials

Identifies any nonconformances to the requirements for the work task to begin

Identifies potential problems

7.3.3. WORK TASK PREPARATORY QUALITY PLANNING MEETINGS

Prior to the start of a work task, the Superintendent conducts a meeting with key company, subcontractor

personnel responsible for carrying out, supervising, or inspecting the work, and interested customer

representatives.

During the meeting, the Superintendent communicates the work task quality requirements and reinforces

heightened awareness for critical requirements. Topics for a work task quality plan meeting include:

Conflicts that need resolution

Required quality documents and a verification of availability to personnel carrying out, supervising, or inspecting the work task

Record keeping requirements and the availability of necessary forms

Review methods and sequences of installation

Special details and conditions

Standards of workmanship

Heightened awareness of critical quality requirements

Quality risks

Work tasks quality inspection form

7.4. WEEKLY QUALITY PLANNING AND COORDINATION MEETINGS

The Superintendent conducts a meeting with key company, subcontractor and supplier personnel

responsible for carrying out, supervising, or inspecting the work, and interested customer representatives.

The meeting is held on a nominal weekly schedule. During the meeting, the Superintendent facilitates

coordination among the participants, communication among the participants, and reinforces heightened

awareness for critical requirements.

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9. NONCONFORMANCES AND CORRECTIVE ACTIONS 9.1. OVERVIEW

Should a nonconformance be identified by an inspection there is a systematic method to control the item,

correct it, and ensure that project quality is not adversely impacted by the event.

A nonconformance is any item that does not meet project specifications or [CompanyName] Quality

System requirements.

9.2. NONCONFORMANCES

9.2.1. MARKING OF NONCONFORMANCES AND OBSERVATIONS

When the Quality Manager, Superintendent, inspector, or customer identifies a nonconformance or an

observation, the item is quickly and clearly marked by tape, tag, or other easily observable signal to

prevent inadvertent cover-up.

9.2.2. CONTROL THE CONTINUATION OF WORK

After the item is marked, the Superintendent determines if work can continue in the affected area:

CONTINUE WORK: When continuing work does not adversely affect quality or hide the defect, work may

continue in the affected area while the disposition of the item is resolved. The Superintendent may place

limitations on the continuation of work.

STOP WORK ORDER: When continuing work can adversely affect quality or hide the defect, work must

stop in the affected area until the disposition of the item resolved. The Superintendent identifies the

limits of the affected area. The Superintendent quickly and clearly identifies the boundaries of the stop

work area.

9.2.3. NONCONFORMANCE REPORT

9.2.3.1. RECORDING OF NONCONFORMANCES

If nonconformances or observed items exist by the work task completion inspection, the Superintendent

or inspector records the nonconformances on a nonconformance report.

The Superintendent sends the nonconformance report to the Quality Manager.

9.2.3.2. QUALITY MANAGER DISPOSITION OF NONCONFORMANCE REPORTS

When the Quality Manager receives a Nonconformance Report, he or she makes an assessment of the

affect the reported nonconformance has on form, fit, and function. The Quality Manager may assign a

disposition of either:

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List of Included Forms

Standard Forms:

Point Of Contact List

Project Organization Chart

Project Quality Communications Plan

Quality Manager Appointment Letter

Project Manager Appointment Letter

Superintendent Appointment Letter

Personnel Certifications and Licenses

Project Personnel Resumes

Project Subcontractor and Supplier List

Training Plan

Training Log

Regulatory Codes and Industry Standards

Project Regulatory Building Codes

Controlled Materials Form

Metals Material Receiving Inspection Report

Material Inspection and Receiving Report

Inspection and Testing Standards

Quality Inspection and Test Plan

Test Equipment Calibration Plan and Log

Quality Controlled Work Task List

Daily Production Report

Work Task Inspection Form

Nonconformance Report

Punch List

Project Completion Inspection Form

System Document Control Form

Project Records Control Form

Project Quality System Audit Form

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[CompanyName][CompanySuffix] Nonconformance Report

Version 20131125

Nonconformance Report Control ID Project ID Project Name

[ProjectNumber] [ProjectName]

Preparer Signature/ Submit Date Quality Manager Signature / Disposition Date

Description of the requirement or specification

Description of the nonconformance, location, affected area, and marking

Disposition

Replace Repair Rework Use As-is

Approval of disposition required by customer representative? Yes No Customer approval signature /date: ___________________________________

Corrective Actions

Corrective actions completed Name/Date:_________________________

Customer acceptance of corrective actions required? Yes No Name/Date:_________________________

Preventive Actions

Preventive actions completed Name/Date:_________________________

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Questions? Call Ed Caldeira 410-451-8006

LIST OF INCLUDED INSPECTION FORMS FOR PLUMBING

Plumbing Insulation

Electric Domestic Water Heaters

Facility Potable-Water Storage Tanks

Facility Sanitary Sewerage

Facility Storm Drainage

Facility Water Distribution

Fuel-Fired Domestic Water Heaters

Plumbing Fixtures

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Plumbing - Plumbing Insulation 22.07.00

Task Completion Inspection Report Project: Phase: Contract#: Subcontractor: Crew:

Compliance Verification

Compliance with initial job-

ready requirements

Compliance with material inspection and tests Compliance with work in process first

article inspection requirements Compliance with work in process

inspection requirements Compliance with Task completion inspection

requirements

Compliance with inspection and test plan

Compliance with safety policies and procedures Reported Nonconformances and incomplete items:

FTQ 2TQ Heightened Awareness Checkpoints

Plumbing and equipment tested and operational before applying Insulation

Area to be insulated is free of rust// scale// dirt// and moisture

Adhesive/Anchors/Staples/Wrapping utilized is compatible with Insulation type

Insulation through penetrations maintains fire rating of structure

Insulation protected from chafe at all supports and contact points

Insulation protected from weathering and moisture intrusion

Operation of valves and actuators not hindered by insulation

Insulation joints sealed

Cladding applied in high abuse/traffic areas Openings/Holes caused by testing closed/repaired

FTQ Scores and Completion Sign-off

Field Mgmt.-91.45.01 Quality 5 4 3 2 1 Notes:

On-Time 5 4 3 2 1 Notes:

Safety 5 4 3 2 1 Notes:

Sign and date*: Cell # / ID #:: Signed: Date: Task has been has been verified complete and in compliance with contract drawings and specifications except for non-conformances and incomplete items reported above.

Quality Score 5 = 100% NO problems 4 = 1 minor problems 3 = Hotspot or 2-3 minor 2 = 6+ or major problems 1 = Excessive problems On-Time Score 5 = On Time 4 = Late 3 = Late by 1 day 2 = Late by 2 days 1 = Late more than 2 days Safety Score 5 = 100% NO problems 4 = 1 minor problem 3 = Hotspot or 2-3 minor 2= 4+ or major problem 1= Injury

Copyright 2012 First Time Quality

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Industry-Specific Information

Available by Division

03 Concrete 08 Openings 27 Communications

04 Masonry 09 Finishes 28 Electronic Safety and

Security

05 Metals 21 Fire Suppression 31 Earthwork

06 Wood Plastic

Composite

22 Plumbing 32 Exterior

Improvements

07 Thermal and

Moisture Protection

23 HVAC

33 Utilities

26 Electrical

For More Information, contact: CaldeiraQuality, LLC • First TimeQuality℠. 410‐451‐8006 • www.firsttimequality.com • [email protected]

For More Information: Contact: FirstTimeQuality

410‐451‐8006

www.FirstTimeQuality.com

[email protected]

http://www.firsttimequality.com/

mailto:[email protected]

http://www.firsttimequality.com/

mailto:[email protected]